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BIFFI GPO 100 Installation, Operation And Maintenance Manual

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Installation, Operation and Maintenance Manual
MAN 571 Rev. 9
February 2025
Biffi GPO
Gas-Hydraulic Actuator
Copyright © Biffi. The information in this document is subject to change without notice. Updated installation, operation and maintenance manuals can be obtained from our website
www.biffi.it or from your nearest Biffi Center: Biffi Italia s.r.l. - Strada Biffi 165, 29017 Fiorenzuola d' A rda (PC) – Italy PH: +39 0523 944 411 – biffi_italia@biffi.it

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  • Page 1 Copyright © Biffi. The information in this document is subject to change without notice. Updated installation, operation and maintenance manuals can be obtained from our website www.biffi.it or from your nearest Biffi Center: Biffi Italia s.r.l. - Strada Biffi 165, 29017 Fiorenzuola d’ A rda (PC) – Italy PH: +39 0523 944 411 – biffi_italia@biffi.it...
  • Page 2 Notes Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 This page is intentionally left blank.

  • Page 3: Table Of Contents

    Installation, Operation and Maintenance Manual Table of Contents MAN 571 Rev. 9 February 2025 Table of Contents Section 1: General Warnings Generalities ......................1 1.1.1 Applicable Regulation ................1 1.1.2 Terms and Conditions ................2 1.1.3 Electrostatic Charge ................2 1.1.4 Noise Emission ..................
  • Page 4 Table of Contents Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 Section 5: Maintenance Periodic Maintenance ..................39 5.1.1 Check and Restore Oil Level in the Gas-Hydraulic Tanks ...40 Extraordinary Maintenance ................42 5.2.1 Lubrication of Mechanism ..............42 5.2.2 Replacing the Seals of the Cylinder ..........43 Dismantling and Tear Down ................44 Section 6: Troubleshooting...

  • Page 5: Section 1: General Warnings

    Biffi Italia s.r.l. pays the highest attention to collecting and verifying the documentation contained in this Installation, Operation and Maintenance (IOM) Manual. However, Biffi Italia s.r.l. is not liable for any mistakes contained in this manual, for damage or accidents due to the use of the latter. The information contained is of exclusive reserved ownership of Biffi Italia s.r.l.

  • Page 6: Terms And Conditions

    MAN 571 Rev. 9 1.1.2 Terms and Conditions Biffi Italia s.r.l. guarantees that all the items produced are free of defects in workmanship and manufacturing materials and meet relevant current specifications, provided they are installed, used and serviced according to the instructions contained in the present manual.

  • Page 7: Identification Plate

    MAN 571 Rev. 9 February 2025 Identification Plate It is forbidden to modify the information and the marks without previous written authorization by Biffi Italia. The plate fastened on the actuator contains the following information (Figures 2 and 3). Figure 2.

  • Page 8: Introducing The Actuator

    Section 1: General Warnings Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 Introducing the Actuator The gas hydraulic GPO actuator is designed and used for the operation of quarter-turn valves (ball valves and plug valves) installed on gas transportation lines, in compressor stations and everywhere a high-pressure gas supply is available.

  • Page 9: Section 2: Installation

    Installation, Operation and Maintenance Manual Section 2: Installation MAN 571 Rev. 9 February 2025 Section 2: Installation Checks Upon Actuator Receipt • Check that the model, the serial number of the actuator and the technical data reported on the identification plate correspond with those of the order confirmation (Section 1.2).
  • Page 10 Section 2: Installation Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 Figure 6. Lifting Points Figure 7. Lifting Points LIFTING POINTS (OBLIGATORY) BALANCING POINT LIFTING POINTS (OBLIGATORY) Installation...
  • Page 11 Installation, Operation and Maintenance Manual Section 2: Installation MAN 571 Rev. 9 February 2025 Figure 8. Lifting Points DO NOT LAY THE ACTUATOR ON TIE-RODS POINT OF SUPPORT • When lifting unbalanced loads, use ropes of different lengths or chains with adjustable length.
  • Page 12 VALVE AND ACTUATOR TOGETHER DO NOT DISASSEMBLE TOP OR BOTTOM COVER. SPRING LOADED. POTENTIAL ELECTROSTATIC CHARGE HAZARD BIFFI IS NOT LIABLE FOR ANY PERSONEL INJURY DUE TO INCORRECT USE REFER TO IOM Figure 10. Horizontal Valve Stem - GPO Configuration GPO suitable for mounting on valve with a horizontal stem.

  • Page 13: Instruction For Transport With Gas-Hydraulic Tanks In Horizontal Position

    If the need for horizontal transport is known at the time of the order, Biffi Italia can provide two isolation ball valves at the inlet of the tanks. In this case it is very easy to isolate the oil tanks, by simply closing the stop valves before boxing.
  • Page 14 Section 2: Installation Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 Disassembly for Shipping: Figure 11. GPO - Main Parts to Consider for Shipping Preparations Loosen the nuts of the compression fittings (R) on the pneumatic connections nipples (S) (Figure 12). Figure 12.
  • Page 15 Installation, Operation and Maintenance Manual Section 2: Installation MAN 571 Rev. 9 February 2025 Remove pneumatic tubes (T) from connection nipple (S) (Figure 13). Figure 13. Step 2 Plug the connection nipple (S) with proper cap plugs (Figure 14). Figure 14. Step 3 CAP PLUG Installation...
  • Page 16 Section 2: Installation Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 Plug the pneumatic pipe ends with plastic plugs for fittings (Figure 15). Figure 15. Step 4 PLASTIC PLUG Re-assembly before “start-up” of actuator: Remove protection plugs from compression fittings (R) and connections (S). Connect pneumatic tubes (T) to connections (S).
  • Page 17 Installation, Operation and Maintenance Manual Section 2: Installation MAN 571 Rev. 9 February 2025 When torque limiting devices are furnished, proceeded as follows: (See Figure 16) Disassembly for shipping : Remove tubes (T1 and T2) on connections (S1, S2) by loosening the nuts of the compression fittings (R).

  • Page 18: Procedure To Follow If Oil Leaks From The Tanks Into The Pneumatic Valves

    Section 2: Installation Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 2.2.2 Procedure to Follow If Oil Leaks from the Tanks into the Pneumatic Valves NOTICE If the actuator tanks are kept in a horizontal axis by mistake, and the oil inside them flows into the pneumatic connection pipes and into the control pneumatic valves, it is necessary to wash the interior of valves and pipes with dry air (high flow, low pressure): connect an air or a dry nitrogen supply to the threaded hole of the...

  • Page 19: Storage

    For the biggest actuator models, the actuator flange can be machined in accordance with the valve flange dimensions. The yoke is bored with keyways for coupling to the valve stem, the dimensions of which are according to Biffi base tables SCN2600 and SCN2601 (Tables 1 to 6). Installation...
  • Page 20 Section 2: Installation Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 Figure 17. Coupling Dimensions - Actuator Models 0.3 to 6 (SCN6200 - Rev. 15/10/19) DRIVE SLEEVE Ød +0.1 Ød Ød ±0.2 Ød N. THREADED HOLES PCD, NUMBER AND SIZE ACCORDING TO ISO 5211 (BUT THE HOLES ARE ON CENTERLINE INSTEAD OF...
  • Page 21 Installation, Operation and Maintenance Manual Section 2: Installation MAN 571 Rev. 9 February 2025 Figure 18. Coupling Dimensions - Actuator Model 14 (SCN6201 - Rev. 16/06/20) DRIVE SLEEVE Ød +0.1 Ød Ød ±0.2 Ød N. THREADED HOLES PCD, HOLES, NUMBER AND SIZE ACCORDING TO ISO 5211 FLOW LINE Ø...
  • Page 22 Section 2: Installation Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 Figure 19. Coupling Dimensions - Actuator Models 18 and 32 (SCN6201 - Rev. 16/06/20) DRIVE SLEEVE Ød +0.1 Ød Ød ±0.2 Ød N. THREADED HOLES P.C.D. AND HOLES SIZE ACCORDING TO ISO (NUMBER AND THREAD DEPTH IS W D10 NOT ACCORDING TO ISO 5211)
  • Page 23 Installation, Operation and Maintenance Manual Section 2: Installation MAN 571 Rev. 9 February 2025 Figure 20. Coupling Dimensions - Actuator Model 50 (SCN6201-1 - Rev. 15/10/19) DRIVE SLEEVE Ød +0.1 Ød Ød ±0.2 Ød N. THREADED HOLES FLOW LINE Ød +0.2 +0.1 TOP VIEW OF THE SCOTCH YOKE MECHANISM...
  • Page 24 Section 2: Installation Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 Figure 21. Coupling Dimensions - Actuator Models 65 and 80 (SCN6201-3 - Rev. 19/06/20) DRIVE SLEEVE Ød +0.1 Ød Ød ±0.2 Ød N. THREADED HOLES P.C.D. AND HOLES SIZE ACCORDING TO ISO 5211 (NUMBER AND THREAD DEPTH IS NOT ACCORDING TO ISO 5211) FLOW LINE...
  • Page 25 Installation, Operation and Maintenance Manual Section 2: Installation MAN 571 Rev. 9 February 2025 Figure 22. Coupling Dimensions - Actuator Model 100 (SCN6201-5 - Rev. 22/07/22) DRIVE SLEEVE Ød +0.1 Ød Ød ±0.2 Ød N. THREADED HOLES P.C.D. NUMBER AND HOLES SIZE ACCORDING TO ISO (BUT THE HOLES ARE ON CNTERLINE AND THREAD DEPTH IS NOT ACCORDING...
  • Page 26 February 2025 MAN 571 Rev. 9 If required, for the base models size 0.3 to 6, Biffi can supply an insert bush with unmachined bore in accordance with Biffi base table SCN6202. On request, the insert bush bore can be machined by Biffi to couple the valve stem, provided its dimensions match the maximum stem acceptance of the bush according to Biffi table TN1005 (ask factory or refer to TDS), and refer to Figure 13.

  • Page 27: Assembly Procedure

    Installation, Operation and Maintenance Manual Section 2: Installation MAN 571 Rev. 9 February 2025 2.4.2 Assembly Procedure NOTICE Failure to comply with the following procedures may void product warranty. WARNING Installation, commissioning and maintenance and repair works should be carried out by qualified staff. A non-conforming assembly could be the source of serious accidents.

  • Page 28: Pneumatic Connections

    Section 2: Installation Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 Table 8. Nuts Tightening Torque Threading Tightening Torque (Nm) 1100 1400 1700 The screwing values in Table 8 were calculated considering the materials ASTM A320 L7 for screws or tie rods and ASTM A194 Grade 2H for the nuts.

  • Page 29: Electrical Connections (If Any)

    Installation, Operation and Maintenance Manual Section 2: Installation MAN 571 Rev. 9 February 2025 Electrical Connections (If Any) WARNING Use components appropriate as for type, material and dimensions. NOTICE The connections should be made by qualified staff. Before carrying out any operation, cut line power off. Safety provisions: 2006/95/EC: Directive for low voltage equipment (until 19 April 2016) 2014/35/EU from 20 April 2016...

  • Page 30: Commissioning

    Section 2: Installation Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 Commissioning NOTICE Check that values of electrical supply to the control group (if foreseen) are compatible with those on the plate on the junction box (Figure 24). WARNING Installation, commissioning and maintenance and repair works should be made by qualified staff.

  • Page 31: Section 3: Operation And Use

    Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 571 Rev. 9 February 2025 Section 3: Operation and Use Operation Description The supply gas pressurizes the oil contained in the gas-hydraulic tank relevant to the operation to carry out opening or closing (Figure 25). Oil, (Figure 27), arrives to the manual hydraulic control group and pressurizes a chamber of the cylinder: this starts the linear motion of the piston and the consequent rotation motion of the scotch yoke, to which the valve stem is coupled.
  • Page 32 Section 3: Operation and Use Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 Figure 25. Operating Diagram OPEN CLOSE T.E. ELECTRONIC CONNECTION TO SOLENOID VALVES AND TO MICROSWITCHES EXHAUST AUXILIARY GAS SUPPLY E.M. GAS SUPPLY GAS SUPPLY CONNECTION CONNECTION (DOWNSTREAM THE VALVE) (UPSTREAM THE VALVE)
  • Page 33 For any particular requirements, it is advisable to contact Biffi sales offices, which will provide the most suitable and convenient solutions to the various needs (Figure 26).

  • Page 34: Residual Risks

    Section 3: Operation and Use Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 Figure 27. Flow Regulator Valves The speed of operation can be adjusted on site by two flow control valves (see Figure 27 and Section 3.6) Residual Risks WARNING It is recommended to pipe exhaust gas.

  • Page 35: Local Hydraulic Manual Operation

    Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 571 Rev. 9 February 2025 Figure 28. Double Solenoid Valve with Manual Control • Arrange the distributor to the “Automatic” position (Figure 29). • Operate the manual control lever of the double solenoid valve in the control group, relevant to the operation to carry out opening or closing (Figure 25).

  • Page 36: Remote Operation

    Section 3: Operation and Use Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 3.3.3 Remote Operation • In case of remote control, arrange the distributor to “Automatic” position (Figure 29), and from the control room send the electric signal corresponding to the operation to carry out (opening or closing).

  • Page 37: Calibration Of The Angular Stroke

    Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 571 Rev. 9 February 2025 Calibration of the Angular Stroke The angular stroke of the yoke can be adjusted between 82° and 98° (±4° with respect to the nominal positions of complete opening and closing) by means the mechanical stops screwed into the left side of the housing (open valve) and into the end flange of the pneumatic cylinder (closing) (Figure 30).
  • Page 38 Section 3: Operation and Use Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 For the adjustment of the mechanical stop on the end flange of cylinder, follow these steps (Figure 32): • Remove with the specific wrench (c1) the plug (t). •...

  • Page 39: Calibration Of Microswitches (If Foreseen)

    Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 571 Rev. 9 February 2025 Calibration of Microswitches (If Foreseen) (Refer to Safety Instructions Manual of the supplied limit switch box) WARNING Refer only to technical documentation related to installed switch-box model. NOTICE Operate only the microswitch corresponding to the direction of operation being carried out, as clearly reported on the microswitch.

  • Page 40: Calibration Of The Operation Time

    Section 3: Operation and Use Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 If the index (Figure 36), does not signal the proper position of the valve but is turned by 90°: • Remove the roll pin placed on the position indicator (index). •...
  • Page 41 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 571 Rev. 9 February 2025 Figure 37. Adjustment of Operation Time and Oil Levels Closing operation time Opening operation time To carry out the adjustment, use an adequate Allen wrench and follow these steps (Figure 38): •...

  • Page 42: Section 4: Operational Tests And Inspections

    Section 4: Operational Tests and Inspections Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 Section 4: Operational Tests and Inspections NOTICE To ensure the guaranteed SIL grade, according to IEC 61508, the functionality of actuator must be checked with regular intervals of time, as described in the Safety Manual.

  • Page 43: Section 5: Maintenance

    Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 571 Rev. 9 February 2025 Section 5: Maintenance NOTICE Before executing any maintenance operation, it is necessary to close the pneumatic supply line and discharge pressure from the cylinder of the actuator, from the control unit and from the accumulator tank (if foreseen).

  • Page 44: Check And Restore Oil Level In The Gas-Hydraulic Tanks

    Section 5: Maintenance Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 5.1.1 Check and Restore Oil Level in the Gas-Hydraulic Tanks Bring the actuator to the completely open or completely closed position. • Wait for a few minutes before checking. •...
  • Page 45 Use an equivalent or better product in compliance with the oil proposed in the actual scope of supply Equivalent oils by Biffi. Your oil supplier can verify and propose an alternative product at your responsibility. Low Temperature Conditions (to -46 °C):...

  • Page 46: Extraordinary Maintenance

    If the service is not special (i.e., oxygen, hydrogen or other mentioned during the offer stage). Use an equivalent or better product in compliance with the grease proposed in the actual scope of supply by Biffi. Your grease supplier can verify and propose an alternative product at your responsibility. Maintenance...

  • Page 47: Replacing The Seals Of The Cylinder

    Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 571 Rev. 9 February 2025 5.2.1 Replacing the Seals of the Cylinder (Section 7.2 - Figure 41: Hydraulic Cylinder) • Measure the protrusion edge of the setting-screw (11) referred to the surface of the end flange of the cylinder (13), so to easily restore the calibration (Section 3.4) once the maintenance operations are over •...

  • Page 48: Dismantling And Tear Down

    Section 5: Maintenance Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 Dismantling and Tear Down Before starting the disassembly, a large area should be created around the actuator to allow any kind of movement without problems of further risks created by worksite. WARNING Before disassembling the actuator, it is necessary to close the pneumatic feed line and discharge pressure from the cylinder of the actuator, from the control unit and from...

  • Page 49: Section 6: Troubleshooting

    Actuator does Wrong position of the distributor of the not work Restore correct position manual hydraulic group Failure of the control group Call Biffi Customer Service Low supply pressure Restore (Section 1.4) Low supply pressure Restore (Section 1.4) Actuator too slow Wrong calibration of flow regulator valves Restore (Section 3.6)

  • Page 50: Section 7: Layouts

    Section 7: Layouts Spare Parts Order For spare parts order to the relevant Biffi office, please make reference to Biffi order confirmation concerning all the supply, and serial number of the actuator (Section 1.2) for any specific spare part for a specific actuator model.

  • Page 51: Parts List For Maintenance And Replacing Procedure

    Installation, Operation and Maintenance Manual Section 7: Layouts MAN 571 Rev. 9 February 2025 Parts List for Maintenance and Replacing Procedure Figure 40. Scotch Yoke Mechanism Table 11. Parts List Item Quantity Description Material O-ring Nitrile Butadiene Rubber (NBR) * Yoke bushing Bronze Retainer ring...
  • Page 52 Section 7: Layouts Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 Figure 41. Hydraulic Cylinder Table 12. Parts List Item Quantity Description Material Piston rod bushing Steel + Bronze + PTFE Head flange Carbon steel O-ring NBR * Piston rod seal ring PTFE * + Graphite O-ring...
  • Page 53 Installation, Operation and Maintenance Manual Section 7: Layouts MAN 571 Rev. 9 February 2025 Figure 42. Assembly Kit Table 13. Parts List Item Quantity Description Material Screw Alloy steel Carbon steel Carbon steel Screw Alloy steel Flange Carbon steel Gasket Fiber * Stopper bush Alloy steel...
  • Page 54 Section 7: Layouts Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 Figure 43. Hydraulic Manual Override Table 14. Parts List Item Quantity Description Material Hand pump Carbon steel Hand operated directional control valve Carbon steel Hydraulic flow control valve Carbon steel Layouts...
  • Page 55 Installation, Operation and Maintenance Manual Section 7: Layouts MAN 571 Rev. 9 February 2025 Figure 44. Hand Pump Table 15. Parts List Item Quantity Description Material Ball Stainless steel Delivery valve bush Carbon steel Suction valve bush Carbon steel Spring Stainless steel Suction valve ring Carbon steel...
  • Page 56 Section 7: Layouts Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 Figure 45. Hand Operated Directional Control Valve Layouts...
  • Page 57 Installation, Operation and Maintenance Manual Section 7: Layouts MAN 571 Rev. 9 February 2025 Table 16. Parts List Item Quantity Description Material Handle Aluminum Screw Carbon steel Spring washer Stainless steel Setting screw of relief valve Bronze Lock ring nut Carbon steel Spring Stainless steel...
  • Page 58 Section 7: Layouts Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 Figure 46. Hydraulic Flow Control Valve Table 17. Parts List Item Quantity Description Material Body Carbon steel Body Carbon steel O-ring NBR * Seal ring PTFE * + Graphite Carbon steel Carbon steel Retainer ring...
  • Page 59 Installation, Operation and Maintenance Manual Section 7: Layouts MAN 571 Rev. 9 February 2025 Figure 47. Gas-Hydraulic Tank Table 18. Parts List Item Quantity Description Material Plug Carbon steel Tank Carbon steel Level stik Carbon steel Plate Carbon steel Spring washer Carbon steel Screw Carbon steel...

  • Page 60: Section 8: Gas-Hydraulic Tanks

    Section 8: Gas-Hydraulic Tanks Installation, Operation and Maintenance Manual February 2025 MAN 571 Rev. 9 Section 8: Gas-Hydraulic Tanks Installation, User and Maintenance Manual The tank is supplied internally painted on specific demand of the customer and of the manufacturer of the oil-pneumatic driven actuator on which it will be installed.

  • Page 61: Date Report For Maintenance Operations

    Installation, Operation and Maintenance Manual Section 9: Maintenance Operations MAN 571 Rev. 9 February 2025 Section 9: Date Report for Maintenance Operations Last maintenance operation date: (in factory, on delivery): ……… exec. by : ………… ……… exec. by : ………… ………...
  • Page 62 VCIOM-03742-EN © 2025 Biffi. All rights reserved. Biffi Italia s.r.l. Strada Biffi 165 29017 Fiorenzuola d’Arda (PC) The contents of this publication are presented for informational purposes Italy only, and while every effort has been made to ensure their accuracy,...

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